IP Library Granted Patent US 10,125,506
Granted Patent B2
US 10,125,506 · App. 15/364,839 · Granted Nov 13, 2018

Concrete form system for ballast foundations

Inventors: Paul R. Cusson (West Hartford, CT); Gregory P. Huzyak (Salem, OH); Nathan A. Knapp (Vienna, OH)
Assignee: Northern States Metals Company
E04G9/083E02D27/08E02D27/42E04G9/06E04G13/02F24S25/11F24S25/12H02S20/10
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 10,125,506
App. No.
15/364,839
Granted
Nov 13, 2018
Kind
B2
Abstract

A ballast foundation includes a portable rolled steel enclosure formed from multiple sections and further includes internal bracing. The internal bracing is used to support an upright vertical structural member that connects to an external load (such as a frame structure for a solar array) that is supported by the ballast foundation when the enclosure is filled with concrete.

Claims (30)

1. A ballast foundation system constituted by interacting portable parts configured to a substrate underlying said ballast foundation system, said ballast foundation system comprising:

a) two folding metallic casing sections arranged together to enclose a space over said substrate, said metallic casing sections being configured in two sets of attached opposing walls;

b) a bracing configuration internal to said metallic casing sections, said configuration comprising,

i) at least one longitudinal cross brace locked to a first set of opposing walls;

ii) a plurality of transverse cross braces, each said transverse cross brace attached to said longitudinal cross brace and locked to a second set of opposing walls; and,

iii) at least one substantially vertical upright support attached to said longitudinal cross brace and at least one said transverse cross brace; and,

c) an on-site concrete pour arranged within and contained by said metallic casing sections, said concrete pour conforming to said substrate underlying said ballast foundation system, and rising no higher than a vertical height of said opposing walls of said metallic casing; and, wherein

said metallic casing sections, said bracing configuration, and said concrete pour form a permanent integrated ballast foundation;

said attached opposing walls each comprise upper and lower transverse edges;

lower said transverse edges that are adjacent to said substrate are shaped to contain a portion of said concrete pour, thereby holding said attached opposing walls against said substrate;

said transverse edges comprise a perpendicular lip extending from each said transverse edge; and,

said longitudinal cross brace and said transverse cross braces comprise locking tabs to extend through slots in said opposing walls.

2. The ballast foundation system of claim 1 , wherein said locking tabs fold over an exterior of said enclosed space formed by said opposing walls.

3. The ballast foundation system of claim 1 , wherein said at least one substantially vertical upright support is angularly adjustable with respect to said substrate by means of a connector slot in said longitudinal cross brace.

4. The ballast foundation system of claim 3 , further comprising a plurality of substantially vertical upright supports, and external upper support connecting distal ends of said substantially vertical upright supports.

5. The ballast foundation system of claim 1 , further comprising corner braces arranged at intersections between said two metallic casing sections.

6. The ballast foundation system of claim 1 , further comprising longitudinal ribs on each of said walls of said metallic casing sections.

7. A ballast form to be assembled on-site and placed on a substrate, said ballast form comprising:

a) two metal sheets each having a length, width, and flat outer-face, each said sheet further including V-notches at opposing ends and at least one crease across the width of each said metal sheet for bending to form an enclosure by connecting both metal sheets on-site for placement over said substrate, said enclosure having first and second sets of parallel sidewalls;

b) a bracing system inside said formed enclosure, said bracing system comprising,

i) at least one longitudinal cross brace secured within the enclosure to the first set of parallel sidewalls;

ii) a plurality of transverse cross braces within the enclosure, each said transverse cross brace being secured to said longitudinal cross brace and the second set of parallel sidewalls; and,

iii) at least one substantially vertical support within the enclosure attached to said longitudinal and traverse cross braces; and,

c) concrete contained within the braced enclosure and above said substrate, said concrete having a thickness no greater than the width of said metal sheets; and, wherein

said two metal sheets, said bracing system and said concrete comprise an integral permanent ballast foundation;

said two metal sheets comprise upper and lower transverse edges, and further comprise perpendicular lips extending from said transverse edges; and

said longitudinal cross braces and said transverse cross braces comprise locking tabs extending through complementary slots in said two metal sheets.

8. The ballast form of claim 7 , wherein said substantially vertical support is angularly adjustable using a slot in said longitudinal cross brace.

9. The ballast form of claim 8 , wherein each of said two metal sheets further comprise at least one longitudinal rib.

10. The ballast form of claim 7 , wherein said upper and lower transverse edges comprise a V-shaped removable segment in each said transverse edge at each said crease.

Assignments (4)
CERTIFICATE OF CONVERSION AND NAME CHANGE Recorded Jul 17, 2024
From: NORTHERN STATES METALS COMPANY
To: NORTHERN STATES METALS COMPANY, LLC
Reel/Frame 068406/0598 →
CHANGE OF NAME Recorded Jul 17, 2024
From: NORTHERN STATES METALS COMPANY, LLC
To: SOLAR FLEXRACK LLC
Reel/Frame 068420/0299 →
CHANGE OF NAME Recorded Jul 17, 2024
From: SOLAR FLEXRACK LLC
To: FLEXRACK BY QCELLS LLC
Reel/Frame 068420/0302 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 30, 2016
From: CUSSON, PAUL R.; HUZYAK, GREGORY P.; KNAPP, NATHAN A.
To: NORTHERN STATES METALS COMPANY
Reel/Frame 040467/0697 →
Continuity (2)
Provisional Application 62264658 · Dec 8, 2015
Related Publication 20170159318A1 · Jun 8, 2017
Cited By (3)
US 12,221,759 US 12,231,082 US 12,421,685